Power source selector

ABSTRACT

A computerized method for aiding a user in selecting a proper power source for a welding, heating, or cutting application is provided. The user is prompted to provide data about the process type, power source type, and materials used in the application, and is provided with data regarding typical applications and skill levels required for various applications. By applying the process information provided and providing data prompted by the computer system, the user is guided to select an appropriate power source for the user&#39;s application and general requirements.

FIELD OF THE INVENTION

The present invention is directed to methods for selecting power sourcesfor welding, heating and cutting applications.

BACKGROUND

Metal working processes, such as welding, cutting, and heatingprocesses, and the equipment associated with these processes, can bevery complex. In industrial applications, selecting appropriateprocesses and equipment is a job entrusted to skilled professionals, whodevote entire careers to the study of the processes and equipment usedin these applications, and to methods for perfecting the process forspecific applications.

These processes, however, are also commonly used by a vast array ofunskilled and semi-skilled workers, both professionally, and indo-it-yourself projects and repairs. For these unskilled andsemi-skilled workers, choosing the appropriate process and equipment forthe task at hand can be extremely difficult, particularly given theprocess-specificity of the equipment. Moreover, as metal workingequipment is relatively expensive, it is particularly important fordo-it-yourself project workers and small businesses to select anappropriate piece of equipment for a particular job, and to ensure thatthe selected equipment will be useful for future projects as well.

Metal working, and particularly welding equipment, however, is generallysold through distribution networks that cater largely to industrialcustomers. These distribution networks can be intimidating to a personaluser or home hobbyist as these users are often unsure as to theirwelding equipment needs. Consequently, these users oftentimes avoid thewelding distributors and will alternatively purchase equipment throughretail outlets, such as home centers where they feel more comfortableand less intimidated by the retail sales “generalist” personnel.However, since the home center sales personnel are rarely trained toadvise customers for these applications, a home hobbyist will oftentimes leave the home center with a welder that is not suitable for theirneeds. It can be very difficult, therefore for an infrequent or casualuser of welding or cutting equipment to get the necessary guidance andadvice for selecting metal working processes and equipment for theirapplications. The present invention addresses these issues.

SUMMARY

The present invention provides a method for guiding a user to select apower source and associated equipment for welding, cutting, or heatingapplications. A user is presented with a series of questions and isprovided with associated informational data to guide the user inanswering these questions. These user can specify, for example, awelding process, a power source type, and a material to be welded. Theuser data is compared to a database of available power sources, and theuser is presented with one or more recommendations of power sources thatare suitable for the user's needs.

In one aspect of the invention, a method for aiding a user in selectinga power source for at least one of a welding a cutting, and a heatingprocess is provided. In this method, process attribute data for aplurality welding, cutting, or heating process types is selectivelydisplayed to a user. The user is then prompted to select a process typeand at least one of a power source type and a process material typebased on the process attribute data. The selected processes type and thepower source criteria and material type data provided by the user isthen compared to a database correlating a plurality of power sources torespective power source type, process type, and process material typedata. As a result of the comparison, at least one power source isidentified for the user.

In another aspect of the invention, an alternative method for selectinga power source for at least one of a welding a cutting, and a heatingprocess is provided. In this method, a plurality of process types andcorresponding process attribute data is displayed to a user, and theuser is prompted to select one of the plurality of process types. Theuser is then prompted to select a material that will be used in theprocess. Based on the selected process and material, a power source isrecommended to the user. The user can also be prompted to provide powersource type data defining desired power source characteristics.

These and other aspects of the invention will become apparent from thefollowing description. In the description, reference is made to theaccompanying drawings which form a part hereof, and in which there isshown a preferred embodiment of the invention. Such embodiment does notnecessarily represent the full scope of the invention and reference ismade therefore, to the claims herein for interpreting the scope of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram illustrating a computer system for use in thepresent invention;

FIG. 2 is a flow chart illustrating the basic steps of the power sourceselector of FIG. 1;

FIG. 3 is a detailed flow chart of one embodiment of a power sourceselector of FIG. 1;

FIG. 4 is a screen shot of a display screen of the embodiment of FIG. 3;

FIG. 5 is a screen shot of a screen shot of a help screen of theembodiment of FIG. 3;

FIG. 6 is a screen shot of the screen for selecting a power source for aMIG application;

FIG. 7 is a screen shot of a screen for selecting a power source for anengine-driven application;

FIG. 8 is a screen shot illustrating a power source recommendationscreen;

FIG. 9 is a flow chart of an alternate embodiment of a power sourceselector; and

FIG. 10 is a flow chart of another alternate embodiment of a powersource selector.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the Figures and more particularly to FIG. 1, a blockdiagram of a computer system useful for the present invention is shown.The system includes a central computer or server 10 that is connected toa user computer 16 through a network 18. A power source selector 14 thatprompts or queries the user for data to guide the user in purchasingpower sources and other equipment for welding, cutting, and heatingapplications, is provided on the central computer 10, and is accessibleto a user using the user computer 16 through the network 18. The centralcomputer 10 includes or is coupled to a memory storage device 12 thatincludes a power source database correlating process type, materialtype, and power source type data to available power sources forpurchase. The network 18 can be, for example, a LAN, WAN, wirelessnetwork, internet connection, or other type of wired or wirelesscommunication system. Although a networked system including twocomputers is shown here, it will be apparent that any number ofcomputers could be connected to the system. The user computer, moreover,can be provided as part of a kiosk or other system in a retail outletstore or other location. Additionally, although shown here as part of acomputer network, the power source selector 14 and power source databasecan be provided directly on a stand-alone computer system, stored on aCD, DVD, disc, or other type of memory device, or otherwise be madeavailable to a user.

Referring now to FIG. 2, a block diagram illustrating one embodiment ofa basic power source selector 14 is shown. Initially, in step 20, thepower source selector 14 queries or prompts a user at the user computer16 to select a process type. The process type can be a welding process,a cutting process, or a heating process, and can include, for exampleMIG (Gas Metal Arc Welding or GMAW), TIG (Gas Tungsten Arc Welding orGTAW), or stick (Shielded Metal Arc Welding or SMAW) welding processes,and plasma cutting processes. An engine-driven process can also beselected. Preferably, while selecting a process, the user can eitherview directly or access a help screen 28, either by pressing apredetermined key on a keyboard, accessing a link to a help screen, orby scrolling a mouse over a list of available processes to accessinformational windows that provide data about the specific process. Thehelp screen can provide process attribute data, which can include, forexample, a skill level necessary for the selected process, a list ofapplications appropriate for the process, a list of materialsappropriate for the process, and particular benefits of the selectedprocess that differentiate the selected process from other availableprocess options. The data may also include a list of consumables andaccessory equipment that would be necessary to implement a selectedprocess, comparative costs, or other types of data useful in selectingbetween processes.

After a process is selected in step 20, in step 22, the user is promptedor queried to define the characteristics of an appropriate power sourceby specifying power source type data. The power source type dataindicates characteristics of the power source that are desired by ornecessary to the user. This data can include, for example, a selectionbetween a generator driven power source and a static power source, sizeand weight of the power source, whether the power source is to be mobileor stationary. In addition, the user can specify available input powersources that will be used to supply power to the power source. Forengine driven power source applications, the user can be asked toidentify whether the power source will be used primarily for welding, asa generator, or simultaneously as a welding power source and agenerator. Noise or sound level requirements for the equipment can alsobe specified by the user, as described more fully below.

In step 24, the user is selectively also queried or prompted to enterdata about the type of material to be welded or cut in the selectedprocess. Here, for example, the user can be queried for data about thetype of metal to be used in the application, specifying, for example,whether a material to be cut or welded is aluminum, steel, stainlesssteel, or other types of metals, or combinations of commonly-weldedmetals. A thickness or a range of thicknesses of the material to bewelded or cut can also be acquired. Various other data, including typesof gas and wire available for use, may also be requested.

After the process type, power source type, and process material typedata is acquired from the user, in step 26, the process selector 14compares the available data to the available power sources stored in thedatabase in memory 12, and displays information about one or more powersources that would be suitable for the application to the user. Thisdata can also include, for example, a price of the equipment, or a placeto purchase the equipment. An online ordering system or telephone numberto place an order can also be provided. Suggested auxiliary equipment,consumables, protective clothing, instructional manuals, and options forthe suggested equipment can also be displayed and be made available forpurchase. When no power source meets the criteria established by theuser, the power source selector 14 can prompt the user to start over atstep 20.

Referring now to FIG. 3, a specific embodiment of a power sourceselector 14 constructed in accordance with the present invention isshown. Here, at an initial screen 30, the user is prompted to select aprocess type, as discussed above. The available process type selectionsinclude MIG (GMAW) 32, Stick (SMAW) 34, TIG (GTAW) 36, Engine Drive 38,and Plasma Cutting 40. A Help selection 42 is also available for help inselecting between the various process types, providing information aboutthe benefits for the process types, skill level required, and benefitsassociated with the various processes. Although engine drive is shownhere as a process type selection, it will be apparent that thisselection could also be provided as a power source type, as describedabove.

After the process type is selected, the power source selector 14continues to acquire the data necessary to recommend a power source forthe selected process type. When the engine driven process 36 isselected, the user is queried to specify power source type parameters 22and particularly to specify the balance of generator usage 55 to weldingusage 53. In addition, the system queries the user to determine anacceptable sound or noise level 57 for the power source. Additionally,at step 59, the user is queried regarding the weld process to be used,which can include, for example, MIG, Stick, or TIG. This selectionallows the power source selector 14 to filter between, for example,constant current (CC), constant voltage (CV) or CC/CV systems.

When any other process type is selected, the desired power source isassumed to be a static power source that is connected to an input powerline. Therefore, to specify the power source type 22, the user isqueried to provide an expected input voltage level 45 or a combinationof expected input voltage levels, or a range of expected input powerlevels (e.g. 115, 230 or 115/230 VAC). The user is also queried tospecify a desired level of portability 47 for the power source. Finally,the user is also asked to provide material type data 24 about thematerial to be welded, and particularly metal type 51 and thickness 49.In each of these queries, the questions directed to the user arecustomized based on the selected process and the characteristics of theavailable power sources in the database 12. Therefore, the power sourceselector 14 tailors the questions asked for the specific application,limiting the number of questions that a user is required to answer basedon the process and power source type selected. Thus, as shown here, whenthe Stick process type is selected, the user is queried only about inputvoltage 45 to specify power source type 22, as no additional informationis required. For the plasma cutting selection, only input voltage 45,material type 51, and material thickness 47 is required.

After all of the required data is acquired, the power source selector 14again compares the process and features to the power sources in thedatabase, and recommends, none, one, or a number of possible powersources to the user. The selector 14 can also identify a preferred powersource for the application and/or provide additional data to the userfor selecting between the recommended power sources, as discussed above.

Referring now to FIGS. 4-5, screen shots illustrating one embodiment ofa power source selector as shown in the flow chart of FIG. 3 andprovided at an internet web site are shown. Referring first to FIG. 4,upon entry to the power source selector system 14, a user is presentedwith a screen providing icons or buttons for selecting a process type 20as described with reference to FIG. 3 above. As the user moves a mouseover each of the process icons, the display area 43 directly above thebuttons provides process attribute data or information about theselected process which can include, for example, a skill level necessaryfor properly applying the process or common applications for theselected process, and benefits provided by selecting this process. Ifthe user, having viewed this information, is uncertain about whichprocess to select, the user can select a, “not sure” or “help” category42 which, when selected, provides a more detailed help analysis, asshown in FIG. 5. Once the user enters the “not sure” screen, the usercan again select a process type from the icons in the left hand column,as shown. Process attribute data for each of the processes defined inthe left hand column is provided in a chart format, allowing the user toeasily compare the attributes of the various processes that the user isselecting between. After this selection, the user is prompted to providethe appropriate data for the requested category as if selecting thatprocess from the screen of FIG. 4.

Referring now to FIG. 6, if the MIG button is selected from FIG. 4 or 5,the user is prompted to select material type and power source type data.These selections can be made using a “click and drag” selector, andradio button selectors, as shown here, typed into data entry screens, orselected using icons, multiple choice selections, through a series ofautomated question and answer sessions, or in other ways as will beapparent to those of skill in the art. Referring still to FIG. 6, forprocess material type, the user is queried about the type of metal 51 tobe welded or cut, as well as a thickness 49 of the material. As shownhere, the typical thickness of commonly-welded items, such as lawnchairs, boat trailers, or other items, can be provided as an aid to theuser. Furthermore, a variety of commonly welded metals can be specified.Although not shown here, the user can now be queried for available typesof gas or wire for use in a welding application.

As described above, when the MIG button is selected, the user is alsoprompted to enter power source type or characteristic data, including anexpected or desired input voltage level 45, and a level of portability51. The input voltage level can be, as described above 115, 230, 460, orother commonly available voltage levels, although the voltage levels,and also the frequency of AC power, can be varied based on the locationof the user, in accordance with local power standards. The level ofportability 51 can be characterized, as shown here, by querying the userto specify a preferred weight of the power source, and also to specifywhether wheels are desired on the power source. Other mobility factors,such as whether a cart is desirable, can also be included in the query.

Although the screen shown here is tailored to MIG applications, similartypes of data are acquired from the user when selecting the TIG, Stick,and Plasma Cutting process types, as described above with reference toFIG. 3. Also as discussed above, the questions presented to the user orthe data requested from the user can be tailored based on the process,the material, or the types of power sources available for theapplications specified by the user.

Referring now to FIG. 7, when the engine-driven process type isselected, user queries are directed specifically to informationnecessary to specify this type of equipment. Here, the power source type22 is narrowed by determining the level of weld usage 53, e.g. whetherthis is a “basic needs” piece of welding equipment, which might also beused as a generator, or is intended to be used mainly for welding, wherea higher quality arc may be of primary importance. The first selection,therefore, requires the user to establish a quality of arc required forthe power source. The second selector prompts the user to indicategenerator usage 55 and specifically whether the power source is expectedto be used as a generator and a welder simultaneously. The level ofacceptable noise 57 is also requested from the user. Finally, since, asshown here, the welding process 59 was not established initially fromthe first screen, the welding process 59 to be used is selected by theuser. As shown here, the user can select between MIG, Stick, and TIGapplications. Preferably, as described above, skill level data, materialdata, and benefits of using each of these processes can be eitherdisplayed directly to the user or can be made accessible throughselective help screens then making the selection. Material type datacould also be requested.

Referring now to FIG. 8, after all of the appropriate data is provided,and the user activates the “next” button 50, a recommendation 16 is madeto the user. Here, the most appropriate power source based on thedefined application is recommended, and one or more alternative may alsobe provided. As shown here, the user can access links to additional data54 and accessory equipment 52. Additionally, the user can edit theselected parameters 56 from this screen to acquire additionalrecommendations. Although not shown here, based on the parametersselected above, auxiliary equipment, consumables, accessories, clothing,instructional manuals, and other items can also be suggested to theuser, as described above. Furthermore, a link allowing the user topurchase selected items on line can be provided, as can telephonenumbers for ordering the equipment, and information about stores orother outlets where the equipment is available.

Although a specific order for acquiring the data for recommending apower source is described above, it will be apparent that this order canbe varied, and that either more questions or fewer questions can beprovided in the inquiry while achieving similar results. Referring nowto FIG. 9, one alternate example is shown. Here, initially, the user isqueried to determine whether the application is a welding or a cuttingapplication 70. If cutting is selected, the user is queried only fordata appropriate to cutting applications. If welding is selected, theuser is queried for data relating to welding applications. When weldingis selected, the user is initially queried to determine whether the useis for an engine-driven or static machine 72, and appropriate questionsare asked based on the selected type. Subsequently, the user is queriedto specify a weld process type 74. Various other orders for acquiringthe data will be apparent.

Referring now to FIG. 10, another exemplary alternative is shown. Here,the user is initially queried to enter data about the material 14 to bewelded or cut 60, including metal type and thickness data as describedabove. Based on this selection, appropriate process types 12 can bedisplayed, and the user can be queried to select a process 64. After thematerial and process are selected, a display of power source types canbe provided 66 and the user queried to specify a power source type 68.As described above, help screens can be provided to the user to help theuser select an appropriate power source and process for their individualneeds. A power source can then be recommended.

Although a number of specific methods are described, it will be apparentthat many ways for structuring the flow of questions to a user areavailable. It should, therefore, be understood that the methods andapparatuses described above are only exemplary and do not limit thescope of the invention, and that various modifications could be made bythose skilled in the art that would fall under the scope of theinvention. To apprise the public of the scope of this invention, thefollowing claims are made:

1. A computer system for aiding a user in selecting a power supply forat least one of a welding, a cutting, and a heating process, thecomputer system comprising: a user computer; a network connected to theuser computer; and a central computer connected to the user computerthrough the network, the central computer comprising a memory storagedevice storing a database correlating a plurality of power sources to atleast one of process data, material data, power source data, and processattribute data; wherein the central computer is programmed to: displayat least one of a process data selection, a power source data selection,and a material data selection and prompt the user to select at least oneprocess data selection, power source data selection, and material dataselection from the user computer; compare the selected process dataselection, power source data selection, or material data selection tothe database to correlate a plurality of power sources to the selectedprocess data selection, power source data selection, and material dataselection; and display at least one power source based on the selectedone of the power source data selection, process data selection, orprocess material data selection for the user.
 2. The computer system asrecited in claim 1, wherein the central computer is further programmedto display process attribute data associated with at least one of thedisplayed process data selections, the process attribute data includingat least one of a skill level necessary for applying the process, acommon application for the selected process, and a benefit provided bythe selected process.
 3. The computer system as recited in claim 1,wherein the central computer is further programmed to prompt a user toselect a help category, and, when the help category is selected, todisplay a chart allowing a user to display process attributes for aselected process.
 4. The computer system as recited in claim 2, whereinthe central computer is further programmed to prompt a user to select amaterial data selection and a power source data selection using a clickand drag selector.
 5. The computer system as recited in claim 1, whereinthe central computer is further programmed to prompt the user to selecta process data selection from at least one of a GMAW, a GTAW, and anSMAW welding process.
 6. The computer system as recited in claim 1,wherein the central computer is further programmed to prompt the user toselect the power source data selection from at least one of an enginedrive and a static power source.
 7. The computer system as recited inclaim 1, wherein the central computer is further programmed to promptthe user to select the process material data selection as at least oneof a metal and a material thickness.
 8. The computer system as recitedin claim 1, wherein the central computer is further programmed to promptthe user to select at least one of a noise level, a weld usage level,and a generator usage level when the selected power source is an enginedrive.
 9. The computer system as recited in claim 1, wherein the centralcomputer is further programmed to prompt the user to select an inputvoltage level when the selected power source is a static power source.10. The computer system as recited in claim 1, wherein the centralcomputer is further programmed to prompt the user to select a level ofmobility required for the selected power source.
 11. The computer systemas recited in claim 1, wherein the central computer is furtherprogrammed to prompt the user to select between a welding process typeand a cutting process type.
 12. The computer system as recited in claim1, wherein the central computer is further programmed to prompt the userto select between a welding process and a plasma cutting process. 13.The computer system as recited in claim 1, wherein the network comprisesat least one of an internet link, a LAN, a WAN, and a wireless network.14. The computer system as recited in claim 1, wherein the centralcomputer is further programmed to provide an indicator of a thickness ofat least one commonly-welded item to the user.
 15. The computer systemas recited in claim 1, wherein the central computer is furtherprogrammed to prompt the user to select between a low usage, a mediumusage, and a frequent usage parameter to identify the frequency ofwelding.
 16. A method for aiding a user in selecting a power supply forat least one of a welding, a cutting, and a heating process, the methodcomprising: providing a display at a user computer prompting a user toselect at least one of a process data selection, a material dataselection, and a power source data selection, and transmitting the userselection through a network to a central computer; and comparing theuser selection to a database stored in a memory storage device connectedto the central computer and correlating the selected at least one of aprocess data selection, material data selection, power source dataselection, and process attribute data to power source data stored in thedatabase to identify a power source that correlates with the user data;transmitting a power source selection to a display at the user computer;and displaying the power source selection to the user.
 17. The method asrecited in claim 16, further comprising the step of providing a displayat the user computer prompting the user to access process attribute dataassociated with at least one of the displayed process types, the processattribute data including at least one of a skill level necessary forapplying the process, a common application for the selected process, anda benefit provided by the selected process; transmitting the userselection to the central computer; retrieving the process attribute datafrom the memory storage; and displaying the process attribute data atthe user computer.
 18. The method as recited in claim 16, furthercomprising the step of displaying a prompt at the user computer toprovide access for the user to select a help category, and, when theprompt is activated, transmitting the request to the central computer,retrieving a chart from the memory storage and displaying processattribute data at the user computer.
 19. The computer system as recitedin claim 16, wherein the step of prompting a user to select at least oneof a process data selection, material data selection, and a power sourcedata selection comprises displaying a click and drag selector andprompting the user to select a material data selection and a powersource data selection using the click and drag selector.
 20. The methodas recited in claim 16, wherein the step of prompting a user to select amaterial data selection comprises prompting the user to select at leastone of a metal and a material thickness at the user display andtransmitting the selected at least one of a metal and a materialthickness to the central computer.